Inspection Procedure

CAUTION:

Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are working on the high-voltage system.
After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.

HINT:

At least 5 minutes is required to discharge the high-voltage capacitor inside the w/ converter inverter assembly.

READ OUTPUT DTC (HV)

Connect the intelligent tester to the DLC3.
Turn the ignition switch to the ON position.
Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES.

Read output DTCs. (See DTC CHECK / CLEAR )

Result:

The DTCs shown in the table below are output

OUTPUT DTC (HV)

DTC No.	Relevant Diagnosis
P0A1D	HV ECU circuit malfunction
P0A2B, P0A2C, P0A2D	Motor temperature sensor circuit
P0A37, P0A38, P0A39	Generator temperature sensor circuit
P0A3F, P0A40, P0A41	Motor resolver circuit
P0A4B, P0A4C, P0A4D	Generator resolver circuit
P0A60, P0A63	Motor current sensor circuit
P0A72, P0A75	Generator current sensor circuit
P0A78	Motor inverter function malfunction
P0A7A	Generator inverter function malfunction
P0A90	Motor function malfunction
P0A92	Generator function malfunction
P0A93	Inverter cooling system
P0A94 (Except for 554 and 555)	Boost converter circuit
P0AA1, P0AA2, P0AA4, P0AA5	System main relay circuit
P3004, P0AA6	High-voltage system
P0A79 (Except for 693, 694, 812, 813, and 814)	Rear motor inverter function malfunction
P0A45, P0A46, P0A47	Rear motor resolver malfunction
P0A69, P0A6C, P0A55	Rear motor current sensor circuit
P0A1A, P0A1B, P0A1C	MG ECU circuit malfunction

HINT:

Turning the ignition switch to the ON position with the service plug grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.
P0A79-693 and P0A78-694 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

YES: GO TO DIAGNOSTIC TROUBLE CODE CHART

NO: GO TO NEXT STEP

CONNECTION CONDITION OF HV CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
1. Check the connections of the HV control ECU connectors.
  OK:
  
  Connectors are connected securely and there is no poor connection.
Fig 1: Checking Connection Condition Of HV Control ECU Connector (Looseness And Poor Contact)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP
CHECK CONNECTION CONDITION OF MG ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
CAUTION: Be sure to wear insulated gloves.
1. Turn the ignition switch off and remove the service plug grip. (See PRECAUTION )
  NOTE: Do not put the vehicle into the READY-on state with the service plug grip removed as this may cause a malfunction.
2. Remove the inverter cover. (See INVERTER WITH CONVERTER )
  NOTE:
  - Wrap the interlock round terminal for the inverter cover with vinyl tape to prevent it from shorting to ground.
  - Prevent water in the reservoir tank from entering the inverter.
  - Removing the inverter cover causes the MG ECU board to be exposed. Therefore, temporarily install the inverter cover for each area to be inspected.
3. Check the connections of the MG ECU connectors.
  OK:
  
  Connectors are connected securely and there is no poor connection.
Fig 2: Checking Connection Condition Of MG ECU Connector (Looseness And Poor Contact)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CONNECT SECURELY

OK: GO TO NEXT STEP
CHECK W/ CONVERTER INVERTER ASSEMBLY (REAR MOTOR)
CAUTION: Be sure to wear insulated gloves.
1. Check that the service plug grip is removed.
2. Check that the bolts for the three-phase AC cable for Rear Motor are tightened to the specified torque.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Fig 3: Identifying Bolts For Three-Phase AC Cable For Rear Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: TIGHTEN THEM TO SPECIFIED TORQUE

OK: GO TO NEXT STEP

INSPECT REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY

CAUTION: Be sure to wear insulated gloves.

Check that the service plug grip is removed.
Disconnect the three-phase AC cable of the rear traction motor w/ transaxle assembly from the inverter.

Fig 4: Identifying Rear Traction Motor W/Transaxle Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 5: Identifying Three-Phase AC Cable Of Rear Traction Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - V	109 mΩ or less (20°C)
V - W	109 mΩ or less (20°C)
W - U	109 mΩ or less (20°C)

NOTE: If the Rear Motor temperature is too high, the resistance changes greatly. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

To correct the resistance varying depending on the temperature, use the following formula to calculate the resistance at 20°C.
HINT:
- R20 = Rt / {1 + 0.00393 X (T - 20)}
- R20: Resistance at 20°C(mΩ)
- Rt: Measured resistance (mΩ)
- T: Temperature when the resistance is measured (°C)
Calculate the difference between the maximum and minimum resistance.
Standard resistance:

Difference is 5 mΩ or less

Using a megohmmeter, measure the insulation resistance according to the value(s) in the table below.

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - Body ground	10 MΩ or higher
V - Body ground	10 MΩ or higher
W - Body ground	10 MΩ or higher

NG: Go to step 8

OK: GO TO NEXT STEP

CHECK HARNESS AND CONNECTOR (MG ECU - REAR MOTOR RESOLVER)

Disconnect the I21 connector from the MG ECU.
Disconnect the M18 rear motor resolver connector.

Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position.

Standard Voltage

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
RRF (I21-21) - Body ground	Below 1 V
RRFG (I21-22) - Body ground	Below 1 V
RSN (I21-29) - Body ground	Below 1 V
RSNG (I21-30) - Body ground	Below 1 V
RCS (I21-11) - Body ground	Below 1 V
RCSG (I21-23) - Body ground	Below 1 V

NOTE: Turning the ignition switch to the ON position with the MG ECU connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing the inspection.

Turn the ignition switch off.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
RRF (I21-21) - RRF (M18-1)	Below 1 Ω
RRFG (I21-22) - RRFG (M18-4)	Below 1 Ω
RSN (I21-29) - RSN (M18-2)	Below 1 Ω
RSNG (I21-30) - RSNG (M18-5)	Below 1 Ω
RCS (I21-11) - RCS (M18-3)	Below 1 Ω
RCSG (I21-23) - RCSG (M18-6)	Below 1 Ω

Fig 6: Identifying MG ECU And Rear Motor Resolver Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
RRF (I21-21) or RRF (M18-1) - Body ground	10 kΩ or higher
RRFG (I21-22) or RRFG (M18-4) - Body ground	10 kΩ or higher
RSN (I21-29) or RSN (M18-2) - Body ground	10 kΩ or higher
RSNG (I21-30) or RSNG (M18-5) - Body ground	10 kΩ or higher
RCS (I21-11) or RCS (M18-3) - Body ground	10 kΩ or higher
RCSG (I21-23) or RCSG (M18-6) - Body ground	10 kΩ or higher

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

OK: GO TO NEXT STEP

INSPECT REAR MOTOR RESOLVER

Measure the resistance according to the value(s) in the table below.

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
RRF (M18-1) - RRFG (M18-4)	7.65 to 10.2 Ω
RSN (M18-2) - RSNG (M18-5)	12.6 to 16.8 Ω
RCS (M18-3) - RCSG (M18-6)	12.6 to 16.8 Ω

Using a megohmmeter, measure the insulation resistance according to the value(s) in the table below.

Fig 7: Inspecting Rear Motor Resolver

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
RRF (M18-1) - RSN (M18-2)	10 MΩ or higher
RRF (M18-1) - RCS (M18-3)	10 MΩ or higher
RSN (M18-2) - RCS (M18-3)	10 MΩ or higher
RRFG (M18-4) - RSNG (M18-5)	10 MΩ or higher
RRFG (M18-4) - RCSG(M18-6)	10 MΩ or higher
RSNG (M18-5) - RCSG (M18-6)	10 MΩ or higher
Each terminal listed above - Transaxle housing	10 MΩ or higher

NG: REPLACE REAR TRACTION MOTOR W/ TRANSAXLE ASSEMBLY

OK: REPLACE W/ CONVERTER INVERTER ASSEMBLY

CHECK FRAME WIRE NO. 3

NOTE: Be sure to wear insulated gloves.

Disconnect the three-phase AC cable for Rear Motor from the rear traction motor w/ transaxle assembly.

Fig 8: Identifying Frame Wire No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the three-phase AC cable from the rear traction motor.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for open)

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - U	Continuity
V - V	Continuity
W - W	Continuity

Standard Resistance (Check for short)

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - V	No continuity
V - W	No continuity
W - U	No continuity

NG: REPLACE FRAME WIRE NO. 3

Fig 9: Identifying Three-Phase AC Cable For Rear Motor

OK: GO TO NEXT STEP

INSPECT EXTENSION WIRE ASSEMBLY

Remove the rear traction motor w/ transaxle assembly. (See OIL PUMP ASSEMBLY )
Remove the extension wire assembly from the rear traction motor w/ transaxle assembly. (See OIL PUMP ASSEMBLY )

Using a megohmmeter, measure the insulation resistance according to the value(s) in the table below.

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - Shield shell	10 MΩ or higher
V - Shield shell	10 MΩ or higher
W - Shield shell	10 MΩ or higher

Measure the resistance according to the value(s) in the table below.

Standard Resistance

TESTER CONNECTION AND SPECIFIED CONDITIONS

Tester Connection	Specified Condition
U - U	Below 1 Ω
V - V	Below 1 Ω
W - W	Below 1 Ω

NG: REPLACE EXTENSION WIRE ASSEMBLY

Fig 10: Inspecting Extension Wire Assembly

OK: REPLACE REAR TRACTION MOTOR W/TRANSAXLE ASSEMBLY